Process for making a self-closing, resealable package

ABSTRACT

A process for making a resealable package that that is formed from a packaging material, which is coated with cohesive material with a liner covering a portion of the cohesive material such that when the laminate is folded about an article to be enclosed the liner inhibits some of the cohesive from sticking to itself. The packaging material may further include a strip of pressure sensitive adhesive for resealing the package.

CROSS REFERENCE

[0001] This application is a continuation of application Ser. No.09/935,319, filed Aug. 21,2001.

FIELD OF INVENTION

[0002] This invention relates to a process for making a resealable,reusable mailer package which can be used for shipping goods to aconsumer, who may then re-use the same package, if necessary, forre-mailing the goods back to the sender.

BACKGROUND ART

[0003] Methods for making various types of resealable packages areknown. For Example, a method for making resealable packages is disclosedin Forman, U.S. Pat. No. 6,139,662. This method relates to makingflexible packages that have an openable and resealable interlockingclosure. The resealable closures are formed from multiple reverselyfanfolded layers of the film from which the package is made. Forman alsodiscloses another method for making a resealable package in U.S. Pat.No. 5,928,749. This method discloses a process that forms a reclosableor easy-opening container with a tack free flap. The tack free flap isformed on line with a portion of the package film, which has been slitaway from the package film and applied to pressure sensitive tape.

[0004] Other disclosed methods for making resealable packages aredisclosed in McClure U.S. Pat. No. 6,122,897 and Schwartz U.S. Pat. No.4,969,309. McClure, like Forman, discloses a method of creating apackage with reclosable, resealable flaps. The package is formed andclosed by securing the flaps on the bottom end of the structure usingpermanent adhesive. After filling the package with product, one topouter flap is engaged by an opposite flap. When the flaps are initiallyclosed during the packaging process, an area of permanent adhesive isapplied on at least one of the flaps to secure the flaps to each otherwhen closed. The method disclosed in Schwartz employs a resealablepackage using a zipper material. The zipper closure comprisesinterlocking beads which effect an openable and reclosable seal.

[0005] In this new millennium and age of the Internet, there is a largeand growing amount of sales of merchandise over the Internet, e.g.,e-commerce, in addition to the ordinary catalog sales and sales fromfulfillment houses. These new types of transactions, in addition to theestablished ones, cause a tremendous increase in the mailing andshipping of goods, both locally and across the country. Inevitably, theincrease in the sales and shipping of goods consequently causes anincrease in returning those same goods to the shipper when the consumeris unsatisfied with the purchase. Therefore, a need exists for aconvenient way to ship goods to consumers that can be easily returned tothe shipper in the same package when necessary to do so. As a result ofthe consumers' need to re-mail unwanted goods back to the sender, thereexists a need for re-usable packages that can serve this purpose, aswell as to a process for making such packages.

SUMMARY OF INVENTION

[0006] The present invention fulfills this need by providing a processof making a resealable re-mailable package that is much simpler thanthat of the prior art. Thus, it satisfies the need for a process ofmaking a resealable package that is simple to use and inexpensive inconstruction and which could easily be made on an industrial scale.

[0007] The present invention relates to a process for providing apackage-forming material comprising the steps of providing a packagingmaterial in the form of at least one sheet having a surface that isreceptive to receiving adhesive or cohesive materials; applying acohesive material to surface portions of the packaging material;applying a release liner upon a portion of the cohesive material; androlling the sheet upon itself to form a roll of package-formingmaterial. If desired, the release liner may have a coating of a pressuresensitive adhesive thereon to assist in temporarily securing the linerto the cohesive material. Also, the method may include the step ofapplying a bead or strip of pressure sensitive adhesive on the cohesivematerial before applying the release liner upon the pressure sensitiveadhesive.

[0008] Advantageously, release liner with or without the bead or stripof adhesive is provided along the entire length of the sheet beforecollecting the material in a roll. Preferably, the process includes thestep of forming a package by placing the packaging material about anarticle to be packaged such that surface portions of the packagingmaterial that include the cohesive material contact other portions thatinclude cohesive material to adhere such portions to each other and forma sealed package which encloses the article.

[0009] In this process, the packaging material may be paper or plasticbut generally would be a laminate of paper and plastic. Preferably, thepackaging material is a laminate that includes a water impermeableplastic film adhesively laminated to a first paper layer, wherein theplastic film has first and second surfaces and the laminate is preparedby corona discharge treating the first surface of the plastic film torender it receptive to adhesives followed by adhesively cold laminatingthe first surface of the plastic film to the first paper layer.Alternatively, the packaging material may be a laminate that includes awater impermeable plastic film adhesively laminated between first andsecond paper layers, wherein the plastic film has first and secondsurfaces and the laminate is prepared by corona discharge treating boththe first and second surfaces of the plastic film to render it receptiveto adhesives followed by adhesively cold laminating the first surface ofthe plastic film to the first paper layer and the second surface of theplastic film to the second paper layer.

[0010] The cohesive material is generally applied to first and secondsurface portions of the packaging material and the package is formed byplacing the first surface of the packaging material above the article tobe packaged and by placing the second surface portion of the packagingmaterial below the article to be packaged, such that the first andsecond surface portions of the packaging material that include thecohesive material contact and adhere to each other to form the sealedpackage which encloses the article.

[0011] In one embodiment, the first and second surface portions of thepackaging material can be provided on one side of a single sheet of thelaminate and then the sheet can be folded around the article to bepackaged to place the cohesive material containing portions inface-to-face orientation so that they can be adhered together to formthe package. For convenience, the cohesive material is typically appliedto one entire surface of the laminate sheet. Alternatively, the firstand second surface portions can be provided as first and second laminatesheets which are and placed above and below the article to be packagedwith the cohesive material containing surface portions in face-to-faceorientation so that they can be adhered together to form the package.

[0012] When a resealable and reusable package is desired, a liner isplaced upon at least part of a cohesive material containing surfaceportion adjacent to where the article is to be packaged to prevent thatpart of the surface portion from adhering to other cohesive materialcontaining surface portions, thus forming a non-adhered margin adjacentthe article after the package is formed. An indication of where thepackage can be opened is provided to enable the package to be opened inthe non-adhered margin, such that the package may be resealed byremoving the liner and contacting the cohesive material containingsurface portions to adhere such portions to each other and form are-sealed package. When the package is opened along the indication, thearticle can be removed from the package for inspection. When the articleis to be returned, it can be simply replaced in the package, with theliner removed so that the package can be re-sealed by contacting thecohesive material containing surface portions to adhere such portionstogether. The indication is preferably an indicia or a pre-printeddotted line which indicates where the package may be cut to open it, andindicia may be provided to indicate where an edge or end of the articleto be packaged should be placed so that it will not be covering themargin. A suitable liner material is paper, plastic, foil or acomposite.

[0013] The plastic film is laminated to the paper layer using pressureand an adhesive that includes a water-based acrylic copolymercomposition or a vinyl acetate ethylene copolymer. Generally, the paperlayer is coated paper, Kraft paper, Bond paper or white paper having athickness of about 3 to 6 mils and the plastic film comprisespolypropylene, polyethylene and polyester and has a thickness of about 1to 3 mils. Different orientations of the laminate may be used. Forexample, the paper layer of the laminate can include a printed surfacewhich is adhered to the plastic film, with the plastic film forming anouter portion of the package. Alternatively, the paper layer canincludes first and second surfaces, with the first surface being aprinted surface, the second surface being s adhered to the plastic filmand the printed surface of the paper layer forming an outer portion ofthe package. Furthermore, the paper layer can include first and secondsurfaces, with the first surface being a metallized surface and thesecond surface adhered to the plastic film so that the metallizedsurface of the paper layer can form a decorative outer portion of thepackage.

[0014] In another variation of the present process, a pressure sensitiveadhesive is applied over at least part of the packaging materialadjacent to where the article is to be packaged, and a liner is placedupon the pressure sensitive adhesive to prevent the pressure sensitiveadhesive from adhering to other portions of the packaging material, thusforming a non-adhered margin after the package is formed. As above, anindication can be provided to show where the package can be opened sothat the package is opened in the non-adhered margin. Thus, the packagemay be resealed by removing the liner and adhering the pressuresensitive material to other surface portions to form a re-sealedpackage. Again, the package can be opened along the indication to removethe article from the package, and it can replaced and resealed in thepackage by removing the liner, and re-sealing the package by contactingthe pressure sensitive material to other surface portions to adhere themtogether. The indication is preferably an indicia or a pre-printeddotted line which indicates where the package may be cut to open it, andindicia may be provided to indicate where an edge or end of the articleto be packaged should be placed so that it will not be covering themargin. A suitable liner material is paper, plastic, foil or acomposite. Advantageously, the packaging material may be a thermoplasticmaterial such as TYVEK.

[0015] After the pressure sensitive adhesive, liner and if desired,indicia, is applied to the packaging material, the material can bestored on a roll and shipped to a user's facility. The user can thendispense the packaging material from the rolls to package articles to beshipped to recipients, consumers, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For a better understanding of the invention, reference is made tothe detailed description of the invention and the accompanying drawingstherein:

[0017]FIG. 1 illustrates a flexible, paper-plastic laminate inaccordance with the invention;

[0018]FIG. 2 illustrates the flexible, paper-plastic laminate coatedwith cohesive and a strip of pressure sensitive adhesive.

[0019]FIG. 3 illustrates an article enclosed inside the resealablepackage formed from the laminate of FIG. 2.

[0020]FIG. 4 illustrates the cohesively coated laminate with areleasable liner and indicia for the placement of an article to bepackaged.

[0021]FIG. 5 illustrates the cohesively bonded edge of the formedresealable package with pressure sensitive adhesive covered by a linerand showing where the package should be cut for opening.

[0022]FIG. 6 illustrates an enclosed package with indicia noting thelocation for cutting the package to open it.

[0023]FIG. 7 illustrates a laminate that is coated with cohesive aroundthe perimeter of the laminate and further includes a strip of pressuresensitive adhesive.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] The present invention provides a process of making package thatmay be resealable. In one embodiment the package is adhesive-free andutilizes cohesive material for sealing and resealing the package. Inanother embodiment, the package is initially sealed by cohesive materialand the package can be resealed by utilizing a strip of pressuresensitive adhesive that is covered and protected by a liner during theinitial sealing of the package.

[0025] The process for making the package of the present inventionprovides a simple, inexpensive construction that is easily used on anindustrial scale. Additionally, the process provides a convenientpackage for re-sending merchandise back to the shipper via the postalsystem.

[0026] The process for making the package includes the steps ofproviding a packaging material in the form of at least one sheet havinga surface that is receptive to receiving adhesive or cohesive materials,applying a cohesive material to surface portions of the packagingmaterial; applying a release liner upon the cohesive material; androlling the sheet upon itself to form a roll of package-formingmaterial. Optionally, a bead or strip of pressure sensitive adhesive canbe applied onto the cohesive material before the release liner isapplied or onto the release liner before it is applied to the cohesivematerial. This facilitates manufacture of the packaging material becausethe cohesive material can be applied to the laminate first, the releaseliner and, if desired, pressure sensitive material applied later,preferably just before the cohesive coated laminate is collected into aroll.

[0027] The package-forming material of the present process may becomprised of paper, plastic, laminate, which may be two-ply orthree-ply, or olefin or thermoplastic film material such as Tyvek®.

[0028] In one embodiment the package-forming material is paper, whichcan be coated paper, Kraft paper, or higher quality paper such as Bondor white paper and has a thickness of from about 3 to 6 mils.

[0029] In another embodiment the package-forming material is plastic,comprised of a polymer selected from the group consisting ofpolypropylene, polyethylene and polyester and has a thickness of fromabout 0.5 to about 3 mils. The plastic packaging material may beoriented or biaxially oriented to impart high-strength thereto.

[0030] Preferably the package forming-material is two-ply laminate, morespecifically, a paper/plastic laminate, wherein a paper layer islaminated to, preferable cold laminated, a plastic layer. The paperlayer of the laminate may include coated paper, Kraft paper, or a higherquality paper such as Bond paper or white paper. The paper layerpreferably comprises Kraft paper and has a thickness of from about 3 toabout 6 mils. The plastic film layer of the laminate may be oriented toimpart high strength thereto. A biaxial orientation is preferred forgreatest strength. The plastic film layer preferably comprises a polymerselected from the group consisting of polypropylene, polyethylene andpolyester and has a thickness of from at least about 0.5 to 3 mils.

[0031] The plastic film layer has a first corona-discharge treatedsurface. This treatment is applied to the plastic immediately before thefirst corona discharge treated surface is adhesively laminated to thepaper layer. This enables a strong bond to be achieved between theplastic and paper to form a paper-plastic film laminate having first andsecond opposed outer surfaces.

[0032] The cold lamination process enables the present packagingmaterial to be manufactured at much higher speeds than when otheradhesives, such as hot melt adhesives, are utilized, for example due tothe additional time required for cooling of the hot melt adhesive beforea secure bond is achieved. If hot melt adhesives were used instead ofcold lamination for joining the plastic film to the paper, the heat ofthe adhesive could cause the film to shrink, thus causing a loss ofstrength. Also, the hot melt adhesive does not achieve its final bondstrength until the adhesive cools, and the plastic film can shrinkbefore this happens. Moreover, a wrinkled or curled product oftenresults due to the difference in the high strength and low strengthareas of the plastic film.

[0033] The use of cold lamination is also advantageous when an orientedor biaxially-oriented plastic film is utilized. It is known that atelevated temperatures, such films relax and lose molecular orientationand strength. For example, when two sheets of biaxially-orientedpolyester film are seamed together, using an ultrasonically-activatedsealing bar to create internal friction and heat within the film, thefilms soften and fuse, with a resultant sealing line that is weak, suchthat the sheets then tend to tear along this line. Similar problems areencountered if an oriented film is exposed to high heat, such as if ahot melt adhesive would be used to join the film to the paper. Coldlamination utilizing a water-based adhesive is essential in order toproduce a laminate that has high strength. Any of a wide range orwater-based adhesives can be used, although a vinyl acetate ethylenecopolymer is preferred. The paper layer absorbs the water from theseadhesives so that a high strength lamination can be rapidly achieved.U.S. Pat. No. 5,244,702 provides further details on this cold laminationprocess, and is incorporated herein to the extent necessary tounderstand this feature of the invention.

[0034] Another benefit of the use of a water-based adhesive is that thistype of adhesive does not require the use of volatile organic solvents.Thus, adverse health and environmental effects are avoided because suchsolvents are not used. Also, additional costs for recovering ordisposing of solvents are not incurred.

[0035] Depending on the type of packaging material desired, thepackaging material may further include an additional paper layer to forma paper-plastic-paper, three-ply laminate sheeting. The extra paperlayer may be desirable for packaging objects with pointed edges orsimply when a packaging material with more strength is desired. As thepaper layers form the inner and outer sides of the packaging material,they can easily be printed with graphics or other indicia prior toapplication of the cohesive material. This enables the packagingmaterial to have one appearance on the outside of the package andanother, different appearance on the side of the material that faces thepackage.

[0036] In a further embodiment, the process relates to providing TYVEK®as the sheet material, since this material has excellent tear and wearresistance.

[0037] The process further includes application of cohesive material tosurface portions of the packaging material. A cohesive material, whichhas the property of only sticking to itself, is applied to surfaceportions of the packaging material. It may be desirable in somesituations to coat less than the entire surface of the packagingmaterial. Accordingly, a screen type roller or rotary screen printingdevice can be used to selectively apply the coating upon only specificareas of the laminate sheeting. In addition, a spray head or series ofspray heads may be used to selectively deposit a particular or randompattern. The pattern can be arranged to achieve a desired cohesiveadhesion of the overall laminate sheeting. Alternatively, the coatingcan be applied to the entire outer surface of the packaging material.

[0038] The type and amount of cohesive coating to be applied will varydepending upon the results desired. For example, when packaging articlesof a standard size, the packager may desire packaging material that doesnot have a layer of cohesive material applied to one entire surface ofthe laminate sheeting. Instead, it may be desirable that the packagingmaterial has cohesive material coated only on the perimeter of thesheeting so that the packaging material does not have cohesive in theareas of the sheeting that would be covered by the article. Thus, lesscohesive would be needed and the packaging material would be less costlyand a more efficient use of cohesive would be provided. After applyingthe cohesive coating, the coated laminate is ready to receive therelease liner and/or pressure sensitive adhesive.

[0039] The resealable feature of the package is provided by applying arelease liner or a strip of pressure sensitive adhesive upon thecohesive material. These would be applied over at least a part of thepackaging material adjacent to where an article to be packaged isplaced. The release liner can be used by itself to prevent the cohesivecoated portions of the laminate from sticking to each other when thepackage is formed. Alternatively, the release liner can be applied uponthe pressure sensitive adhesive to prevent the pressure sensitiveadhesive from adhering to other portions of the packaging material. Foreither embodiment, a non-adhered margin is formed adjacent the packagecontents after the package is formed. After the initial opening of thepackage, the package may be resealed by removing the liner and adheringthe cohesive coated portions together, or by removing the liner andutilizing the pressure sensitive adhesive to secure the panels together.

[0040] Advantageously, the liner or pressure sensitive material isapplied along the entire longitudinal length of the sheet. When theadhesive is applied, it is followed by the application of the releaseliner from a roll of such material directly upon the pressure sensitiveadhesive to prevent that adhesive from sticking to other portions of thesheet. This facilitates the manufacture of the material by enablingcontinuous production. Of course, it is possible to add discontinuousbeads, spots or stripes of pressure sensitive adhesive, provided thatthe beads, stripes or spots are positioned sufficiently close to eachother to enable a reliable and secure bond to be achieved so that thepackage can be reliably closed. When uniform portions of the sheet areto be cut-off and used for wrapping repetitive sized articles to bepackaged, the pressure sensitive adhesive and release liner can beprovided intermittently so that they are position only where needed toreseal the package.

[0041] After manufacturing the package-forming material, the sheet iscollected by rolling upon itself and then is stored on a roll anddispensed therefrom as needed. Thus, after the liner and, if desired,pressure sensitive adhesive and indicia, are applied to the packagingmaterial, the material can be stored on a roll and shipped to a user'sfacility. The user can then dispense the packaging material from therolls to package articles to be shipped to recipients, consumers, etc.

[0042] The release liner and pressure sensitive adhesive provide aresealable feature to the package. That is, to reseal the package afterits initial opening, the user simply pulls off the release liner so thatthe unused cohesive material that was covered by the liner is exposedand can be used to reseal the package closed. Since the cohesivematerial only sticks to itself and only one surface of the packagingmaterial contains the cohesive, when the packaging material is rolledup, the coated surfaces does not make contact with an opposing coatedsurface and no barriers are required to prevent the sheeting fromsticking to itself while stored on the roll.

[0043] For applications, the packaging material can be used in automatedwrapping equipment, wherein the resultant package is automaticallywrapped by a machine generally known in the art, or alternatively thepackaging material can be used in manual wrapping, wherein the packagingmaterial is pulled off and cut from the roll, an article is placed onthe surface of the packaging material and the packaging material isfolded over and about the article.

[0044] In either method of wrapping an article, the opposing coatedsurfaces of the packaging material come into contact and formcohesive-cohesive bonds thereby enclosing the article with anon-adhering margin formed by the placement of a releaseable liner, or astrip of pressure sensitive adhesive or both, so that the package may beresealed a second time after its initial opening by pulling off theliner(s) and exposing the unused cohesive or pressure sensitiveadhesive.

[0045] Alternatively, instead of packaging an article with one unitarysheet of packaging material, it may be desirable to use two sheets ofpackaging material. Each of the two sheets has cohesive material on atleast a potion thereto. Additionally, at least one of the sheets mayhave a bead or strip of pressure sensitive adhesive or the protectiverelease liner or both. The two sheets of packaging material are placedon top of each other such that the cohesively coated surfaces of eachunitary packaging material are opposing surfaces, the article is placedbetween the two sheets and the two sheets are placed in contact witheach other so the contacted portions of the coated surfaces of thesheetings form cohesive-cohesive bonds and the article is enclosedwithin the packaging material, thereby forming a self-closing package.Additionally, a larger release liner may be used and placed between thetwo sheets of packaging material before sealing the article in thepackage so that a non-adhering margin is created to facilitate cuttingopen the package while maintaining a sufficient area to allow resealingof the package after its initial opening. Alternatively, one or both ofthe sheets of the packaging material may include a strip of pressuresensitive adhesive and a protectable liner. Alternatively, both thepressure sensitive adhesive with protectable liner and liner to cover aportion of the cohesive may be employed.

[0046] One feature of the present invention is that it is capable ofpackaging articles of various sizes and shapes. The packaging materialsimply is pulled off the roll in an amount that accommodates theparticular size of the particular article to be packaged.

[0047] In all embodiments, the exterior surface of the package mayinclude a printable surface and such printable exterior surface mayinclude a printed dotted line along the edge positioned so that thepackage may be opened by cutting along the dotted line.

[0048] If a decorative packaging material is desired, the packagingmaterial be metallized or preferably aluminized to provide a decorativeexterior of the package. For example, if a laminate packaging materialis used, the one surface of the paper ply forms the decorated exteriorof the package and the opposing surface is cold laminated to the plasticfilm ply. The plastic film ply is coated with cohesive material so thatwhen the packaging material is in operation, the resultant package hasan exposed decorative outer surface. Furthermore, the plastic may bemetallized as by vacuum deposition to provide a decorative plasticexterior if desirable. If a silver finish is desired, an aluminizedsurface is preferred. Other metallizing treatments, e.g., with copper,iron, or alloys, can be used when other colors are desired.

[0049] It may be desirable that the packaging material have printablesurfaces so that logos, messages, advertisements, emblems, trademarks orsimply, addressee information etc., may be printed on the exterior orinterior surfaces of the formed package. In this regard, the paper plylayer includes a printable surface. The decorative packaging material,if desired, may include a printable surface of metallized paper.Further, the plastic film ply may include a second corona dischargetreated surface to render it receptive to inks so that it may exhibitgraphics that may be desired. The outer surface of the plastic film plymay be metallized as by vacuum deposition to provide a decorativepackage to further provide a printable, decorative package.

[0050] The process may also includes applying indicia on the outersurface of the package in the form of a dotted line or other demarcationto indicate where to cut the package for opening and withdrawal of itscontents while not impairing the resealing capabilities of the package.In this regard, the package may be opened by cutting along a pre-printeddotted line on the exterior surface of the package. The indicia ordotted line is positioned so that the recipient does not cut thepressure sensitive adhesive off the package. Instead, the recipient cutsoff one sealed edge of the package, leaving the pressure sensitiveadhesive unimpaired. The package may then be resealed by utilizing thepressure sensitive adhesive. If pressure sensitive adhesive is not used,the dotted line is positioned so that the recipient cuts off the edge ofthe package immediately adjacent or within the liner so that the outeredge of the cohesive material is cleanly cut off and the package may beopened.

[0051] Thus the process of the invention discloses a method of making aresealable package that may be adhesive-free, i.e., wherein no pressuresensitive adhesive is utilized or one which includes a strip of pressuresensitive adhesive for resealing the package.

[0052] The Laminate Sheeting

[0053] Referring to FIG. 1, shown therein is a unitary, flexiblepaper-plastic laminate sheeting of the process of the present invention.Preferably the package is formed from a single continuous sheet. Thissheet may be made of paper or plastic. For better moisture and tearresistance in an easily printable material, the sheet should be made aseither a two ply laminate (e.g., a paper/plastic laminate) or a threeply laminate (i.e., a paper/plastic/paper laminate). Alternatively, thepackage may be formed from two substrate panels, wherein each substratepanel is formed of the single sheet, two-ply laminate or three-plylaminate.

[0054] In the most preferred embodiments, the process provides alaminate sheeting (S) which includes a paper facing ply 10 whose gauge,weight and quality are appropriate for the mailer package and a plasticfilm ply (12) used for providing moisture resistance.

[0055] The plastic film (12) is oriented, preferably biaxially-oriented,so that it can provide exceptional tensile strength. Such orientation iseffected by stretching the film along at least one and preferably bothof its transverse and horizontal axes to molecularly orient the filmstructure. Preferred plastic materials include polypropylene orpolyester (i.e., MYLAR). The resultant oriented film material has asufficiently high tensile strength to easily and securely retainmaterials within the package during shipping and handling.

[0056] The paper ply (10) is cold laminated by an adhesive (11) to theplastic film ply (12. The inner surface of the plastic ply is renderedwettable to the adhesive by being subjected to a corona-dischargetreatment to enhance the energy at this surface. The plastic film ply(12) does not have to be greater than 3 mils in thickness and isgenerally at least about 0.5 to 1 mil in thickness. The paper base ply(10) is usually thicker to give body to the laminate, and is preferablyabout 2 to 3 mils thick.

[0057] Cold lamination of the plies is effected by a water-basedadhesive, preferably a water-based vinyl acetate ethylene copolymercomposition having an affinity both for the paper ply and the film ply.No heat is applied to the oriented film as the plastic film ply islaminated to the paper ply. The water-based adhesive is fluid at ambienttemperature and is not a hot melt adhesive. A water-based adhesive, oncecured, is not water soluble and is not remoistenable.

[0058] An oriented film, such as the one described, is heat-sensitiveand at elevated temperatures, the film relaxes and loses its molecularorientation and strength. It is known, for example, that when two sheetsof oriented polyester film are seamed together, using anultrasonically-activated sealing bar for this purpose which createsinternal friction and heat within the film, this causes the superposedfilms to soften and fuse. The resultant sealing line is weak, andconsequently, the sheets tend to tear along this line. Clearly then, theutilization of cold lamination is an important feature of the presentinvention that is utilized in order to produce a securely bondedpaper-film laminate of high strength so that the resealable package canwithstand the customary handling of packages in possession of the postoffice or delivery couriers.

[0059] It is to be noted that a synthetic plastic film material, such aspolypropylene, is normally not receptive to adhesives, especiallywater-based adhesives. Therefore, if one were to apply to the surface ofthis film a water based adhesive which is flowable at ambienttemperature or at a temperature somewhat above ambient but not at theelevated temperature of a hot melt adhesive, the adhesive will not beadsorbed by the film.

[0060] The paper ply of the laminate includes coated paper, Kraft paper,Bond paper or white paper and has a printable exterior. The plastic filmply includes a biaxially oriented film. The plastic film comprises:polypropylene, polyethylene, and polyester. The water impermeableplastic film may have a first corona discharge treated surface making itmore receptive to the cohesive material. In addition, the plastic filmmay have a second corona discharge treatment so that its surface isreceptive to inks or other graphic materials. Further, the plastic plyor the paper ply may be metallized or aluminized so that a decorativepackage may be provided.

[0061] Referring to FIG. 2, the exposed surface of a unitary laminatesheeting is entirely coated with cohesive material (13). Additionally, astrip of pressure sensitive adhesive (14) is coated on a portion of thelaminate (S) sheeting so that the package, after opening, can beresealed via the pressure sensitive adhesive as described herein.

[0062] Referring to FIG. 3, the laminate sheeting (S) of the inventionis folded over an article (15) so that a opposing substrate panels (12)are formed with a cohesively coated (13) inner surface and a strip ofpressure sensitive adhesive (14) and liner (30) providing a resealablepackage. The folding of the unitary laminate sheeting defines aninternal space for an enclosed article. When the two opposing substratepanels are aligned and in contact, cohesive-cohesive bonds form betweenthe first and second opposing substrate panels thereby sealing thepackage.

[0063] As shown in FIG. 4, a separate release liner (30) is provided tooverlay and cover the pressure sensitive adhesive coating (14) so thatthe pressure sensitive adhesive is protected before its use. The linermay be provided in conventional forms, including paper, plastic, foil,composite, etc. Also illustrated is a cut line 18 which shows where thepackage is to be opened. This cut line is positioned adjacent therelease liner so that when the package is cut, the release liner allowsthe panels to separate to allow access to the package interior.

[0064] It is also possible to utilize a release liner which is of largersize than the bead or strip of pressure sensitive adhesive. The linercan cover at least part of a cohesive material containing surfaceportion adjacent to where the article is to be packaged to prevent thatpart of the surface portion from adhering to other cohesive materialcontaining surface portions, thus forming a non-adhered margin adjacentthe article after the package is formed. This provides a larger area inwhich the package can be cut to open it while not affecting or cuttingthe strip or bead of pressure sensitive adhesive.

[0065]FIG. 5 shown another embodiment of the process in the form of anadhesive-free resealable package, in which no pressure sensitiveadhesive is added to the laminate sheeting. The laminate sheeting (S) ofthe adhesive-free resealable package instead only has the release liner(30), which is applied over a portion of the cohesive (13) coatedsurface (10) of the laminate. If desired, the release liner may have apressure sensitive adhesive coating thereon to assist in securing theliner to the panel and to prevent movement of the liner during themanufacturing process. Of course, this adhesive must be sufficientlyweak to enable the strip to be easily removed when necessary.

[0066] The release liner covers a portion of the cohesive material suchthat when the laminate sheet (S) is wrapped around a product to bepackaged, a portion of the cohesive material does not come into contactwith another portion of cohesive material and therefore,cohesive-cohesive bonds are not formed at the position of the liner. Thelaminate may further include indicia for marking where the edge of aproduct to be packaged should be placed (19) so that the liner is notcovered when the package is formed. The exterior of the package caninclude a cut line which is immediately adjacent or even within therelease liner. A minimum width of the release liner should not be cutoff when the package is opened so that sufficient cohesive materialremains to allow re-sealing of the package. After the package is opened,the release liner allows the panels to separate to allow access to thepackage interior. When the package is to be re-sealed, the release lineris removed and the previously unused cohesive material can be secured tothe opposite panel for resealing the package.

[0067]FIG. 6 illustrates the formed package of the invention and theindicia which shows where the package can be cut for access to thecontents therein (18).

[0068] Referring to FIG. 7, the laminate may have cohesive materialcoated on only desired portions of the substrate. As shown, the laminatehas cohesive material along the perimeter of the substrate and a stripof pressure sensitive adhesive (14) adjacent to the cohesively coatedperimeter of an edge of the substrate.

[0069] The process of the present invention may utilize a unitarysheeting of olefin material or alternatively, first and second substratepanels wherein the substrate panels are formed from olefin materiale.g., Tyvek®.

[0070] The exterior of the laminate package formed from the process ofthe invention may be the plastic film (12) or the paper ply (10)depending on which is desired. In all embodiments, the exterior surfaceof the package is a printable surface and in one embodiment suchprintable exterior surface has a printed dotted line along the edgepositioned so that a recipient of the package opens the package by usinga pair of scissors or other instrument and cutting along the dottedline. The dotted line is positioned on the exterior surface of thepackage so that the recipient does not cut off the pressure sensitiveadhesive portion of the package so that the package can be resealedafter opening.

[0071] The plastic ply is corona discharge treated so that it isreceptive to inks and graphics. Thus, the plastic film may provide aprintable exterior surface of the package. In addition, a decorativepackage is provided in an embodiment wherein the exterior surface ismetallized or aluminized.

What is claimed is:
 1. A process for providing a package-formingmaterial comprising the steps of: providing a packaging material in theform of at least one sheet having a surface that is receptive toreceiving adhesive or cohesive materials; applying a cohesive materialto surface portions of the packaging material; applying a release linerupon a portion of the cohesive material; and rolling the sheet uponitself to form a roll of package-forming material.
 2. The process ofclaim 1 wherein the release liner has a coating of a pressure sensitiveadhesive thereon to assist in temporarily securing the liner to thecohesive material.
 3. The process of claim 1 which further comprisesapplying a bead or strip of pressure sensitive adhesive on the cohesivematerial before applying the release liner upon the pressure sensitiveadhesive.
 4. The method of claim 3 wherein the bead or strip of adhesiveand release liner are provided along the entire length of the sheet. 5.The method of claim 1 which further comprises forming a package byplacing the packaging material about an article to be packaged such thatsurface portions of the packaging material that include the cohesivematerial contact other surface portions that include cohesive materialto adhere such portions to each other and form a sealed package whichencloses the article.
 6. The process of claim 1 wherein the packagingmaterial is paper, plastic or a laminate of paper and plastic.
 7. Theprocess of claim 1 wherein the packaging material is a laminate thatincludes a water impermeable plastic film adhesively laminated to afirst paper layer, wherein the plastic film has first and secondsurfaces and the laminate is prepared by corona discharge treating thefirst surface of the plastic film to render it receptive to adhesivesfollowed by adhesively cold laminating the first surface of the plasticfilm to the first paper layer.
 8. The process of claim 7, wherein thepackaging material is a laminate that includes a water impermeableplastic film adhesively laminated between first and second paper layers,wherein the plastic film has first and second surfaces and the laminateis prepared by corona discharge treating both the first and secondsurfaces of the plastic film to render it receptive to adhesivesfollowed by adhesively cold laminating the first surface of the plasticfilm to the first paper layer and the second surface of the plastic filmto the second paper layer.
 9. The process of claim 1 wherein thecohesive material is applied to first and second surface portions of thepackaging material and the package is formed by placing the firstsurface portion of the packaging material above the article to bepackaged and by placing the second surface portion of the packagingmaterial below the article to be packaged, such that the first andsecond surface portions of the packaging material that include thecohesive material contact and adhere to each other to form the sealedpackage which encloses the article.
 10. The process of claim 9 whichfurther comprises providing the first and second surface portions of thepackaging material on one side of a single sheet of the laminate andthen folding the sheet around the article to be packaged to place thecohesive material containing portions in face-to-face orientation sothat they can be adhered together to form the package.
 11. The processof claim 10 wherein cohesive material is applied to one entire surfaceof the laminate sheet.
 12. The process of claim 9 which furthercomprises providing the first and second surface portions on first andsecond laminate sheets and placing the sheets above and below thearticle to be packaged with the cohesive material containing surfaceportions in face-to-face orientation so that they can be adheredtogether to form the package.
 13. The process of claim 1 which furthercomprises placing the liner upon at least part of a cohesive materialcontaining surface portion adjacent to where the article is to bepackaged to prevent that part of the surface portion from adhering toother cohesive material containing surface portions, thus forming anon-adhered margin adjacent the article after the package is formed. 14.The process of claim 13 which further comprises providing an indicationof where the package can be opened, wherein the indication enables thepackage to be opened in the non-adhered margin, such that the packagemay be resealed by removing the liner and contacting the cohesivematerial containing surface portions to adhere such portions to eachother and form a re-sealed package.
 15. The process of claim 14 whichfurther comprises opening the package along the indication, removing thearticle from the package, replacing the article in the package; removingthe liner, and re-sealing the package by contacting the cohesivematerial containing surface portions to adhere such portions together.16. The process of claim 14 wherein the indication is an indicia or apre-printed dotted line which indicates where the package may be cut toopen it.
 17. The process of claim 14 which further comprises providingindicia to indicate where an edge or end of the article to be packagedshould be placed so as to not eliminate or obscure the non-adheredmargin.
 18. The process of claim 14 wherein the liner is paper, plastic,foil or a composite material.
 19. The process of claim 1 wherein theplastic film is laminated to the paper layer using pressure and anadhesive that includes a water-based acrylic copolymer composition or avinyl acetate ethylene copolymer, and wherein the paper layer is coatedpaper, Kraft paper, Bond paper or white paper having a thickness ofabout 3 to 6 mils and the plastic film comprises polypropylene,polyethylene and polyester and has a thickness of about 1 to 3 mils. 20.The process of claim 19 wherein the paper layer of the laminate includesa printed surface, the printed surface is adhered to the plastic film,and the plastic film forms an outer portion of the package.
 21. Theprocess of claim 19 wherein the paper layer includes first and secondsurfaces, the first surface is a printed surface, the second surface isadhered to the plastic film and the printed surface of the paper layerforms an outer portion of the package.
 22. The process of claim 21,wherein the paper layer includes first and second surfaces, the firstsurface is a metallized surface, the second surface is adhered to theplastic film and the metallized surface of the paper layer forms adecorative outer portion of the package.
 23. The process of claim 3which further comprises placing the liner upon the pressure sensitiveadhesive and at least part of a cohesive material containing surfaceportion adjacent to where the article is to be packaged to prevent thatpart of the surface portion from adhering to other cohesive materialcontaining surface portions, thus forming a non-adhered margin adjacentthe article and the pressure sensitive adhesive after the package isformed.
 24. The process of claim 23 which further comprises providing anindication of where the package can be opened, wherein the indicationenables the package to be opened in the non-adhered margin, such thatthe package may be resealed by removing the liner and contacting thepressure sensitive adhesive to an opposing surface portion to form are-sealed package.
 25. The process of claim 24 which further comprisesopening the package along the indication, removing the article from thepackage, replacing the article in the package; removing the liner, andre-sealing the package by contacting the pressure sensitive adhesivewith an opposed cohesive material containing surface portion.